This case study shows how MultiSensor AI detected an imminent tray router discharge conveyor failure in a multinational retailer’s fulfillment center. MSAI Connect identified a steady thermal rise caused by a failed tracking roller that forced the belt against side guarding and the tracking unit. The issue was diagnosed and corrected within an agreed inspection window, limiting downtime to one hour instead of a four-hour belt failure. The outcome: three additional hours of operational uptime, $18,000 in avoided labor downtime, and $6,500 in avoided belt replacement costs. A clear example of how continuous thermal monitoring prevents catastrophic conveyor failures before throughput is impacted.